Dismantling
1. Drain the oil from the transfer case.
TRANSFER BOX, ADJUSTMENTS, Changing the transmission oil in the transfer case: except for the North American market.
TRANSFER BOX, ADJUSTMENTS, Transfer case oil change: North American market countries.
2. North American Models: Remove the right catalytic converter.
EMISSION CONTROL SYSTEM, Positive crankcase breather valve: Td4 engine, Right bank catalytic converter: KV6 engine, North American market countries.
3. Remove the right drive shaft seal.
TRANSFER BOX, REPAIR WORKS, Right drive shaft oil seal.
4. Except for North American models: Loosen the nut securing the exhaust manifold heat shield to the transfer case.
5. Except for North American models: Loosen the nut securing the exhaust manifold heat shield to the rear axle drive shaft housing.
6. Except for North American models: Remove the 2 heat shield mounting bolts and remove the heat shield.
7. Remove the engine mount lower cross member.
KV6 ENGINE - MODIFICATION K, Left cylinder head camshafts, lower engine mounting cross member.
8. Turn out 3 bolts of fastening of an arm of a distributing box to the pallet.
9. Turn away 2 bolts of fastening of an arm of a distributing box to a forward plate of the engine.
10. Turn out 5 bolts of fastening of an arm to a distributing box and remove an arm.
11. Turn away 8 bolts of fastening of a back cover to a case of a distributing box.
12. Remove the back cover.
Installation
1. Remove the remnants of the old sealant from the mating surfaces of the cover and transfer case housing.
2. Apply a narrow bead of STC 4600 sealant to the mating surface of the rear cover.
3. Install the rear cover on the transfer box housing, tighten the bolts sequentially to 30 Nm.
4. Install the transfer box bracket and pull the mating surfaces together.
5. Finally tighten all bolts in the following sequence:
- Five bolts securing the bracket to the transfer case with a torque of 50 Nm
- Two bolts securing the bracket to the front engine bracket with a torque of 50 Nm
- Three bolts securing the bracket to the pallet with a torque of 88 Nm.
6. Reinstall the engine mount lower cross member.
KV6 ENGINE - MODIFICATION K, Left cylinder head camshafts, lower engine mounting cross member.
7. Except for North American models: Install the heat shield.
8. With the exception of models for the North American market: Fit the nut securing the heat shield to the transfer box and tighten it to 45 Nm.
9. Except for North American models: Install the bolts securing the heat shield to the transfer case bracket and tighten to 9 Nm.
10. With the exception of models for the North American market: Screw on the nut securing the heat shield to the rear axle drive shaft housing and tighten it to a torque of 25 Nm.
11. Establish an epiploon of the right power shaft.
TRANSFER BOX, REPAIR WORKS, Right drive shaft oil seal.
12. Fill oil into the transfer case housing to the required level.
TRANSFER BOX, ADJUSTMENTS, Changing the transmission oil in the transfer case: except for the North American market.
TRANSFER BOX, ADJUSTMENTS, Transfer case oil change: North American market countries.
13. North American models: Install the right catalytic converter.
EMISSION CONTROL SYSTEM, Positive crankcase breather valve: Td4 engine, Right bank catalytic converter: KV6 engine, North American market countries.
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